System for providing circulating air for a vertical gardening system

ABSTRACT

A flow distribution assembly provides air circulation to a rack-based vertical gardening system. The distribution assembly includes a housing having air inlet and outlet portions. At least one elongated duct has an end fluidly coupled to housing’s air outlet portion, the duct adapted to extend along a shelf of the rack, to an opposite end thereof. A fan is fluidly coupled to the housing’s air inlet portion and is supportable by the rack so that it can direct ambient air into the air inlet portion. The duct has a plurality of openings arranged to direct air at a plant growing area of the gardening system when the distribution assembly is mounted on a rack system. Optionally, the air inlet portion is positionable laterally outboard of plant growing regions of the vertical gardening system.

CROSS REFERENCE TO RELATED APPLICATIONS

The application is a continuation of U.S. Pat. application, Serial No. 16/892,595, filed Jun. 4, 2020, which is a continuation of U.S. Pat. application, Serial No. 15/730,659, filed Oct. 11, 2017, now U.S. Pat. No. 10,694,682, issued Jun. 30, 2020, which claims the benefit of U.S. provisional application, Serial No. 62/549,919, filed Aug. 24, 2017, all of which are hereby incorporated herein by reference in their entireties.

FIELD OF THE INVENTION

The present invention is directed towards a system and method for circulating air to a vertical gardening system.

BACKGROUND OF THE INVENTION

Vertical farming is the practice of producing food and medicine in vertically, stacked layers, vertically inclined surfaces and/or integrated in other structures such as warehouses and other structures that can accommodate growing plants. Vertical farming use indoor farming techniques and controlled-environment agriculture (CEA) technology, where all environmental factors can be controlled. These facilities utilize artificial control of light and watering. Prior methods for circulating air are accomplishing using wall mounted oscillating fans and ceiling mounted HVAC systems. However, this air circulation method is ineffective in a vertical growing configuration and most vertical gardens are too compact for these 20 environmental control methods to be efficient.

Prior methods for carbon dioxide dispersion use piping a plastic line to the back of a wall mounted fan or a carbon dioxide generator mounted at the ceiling in the room. Both methods do not allow for a controlled direction of carbon dioxide. Prior methods of filtering air have been through large “can filters” attached to a fan on the intake side. However, these large can filters occupy a large volume of space. It would be desirable to provide system which improves the circulation of air, improves the distribution of carbon dioxide, and may use smaller filters that occupy less space.

SUMMARY OF THE INVENTION

The present invention is directed towards a system and method for circulating air and which may circulate carbon dioxide and provide light to a vertical gardening system. Traditional methods of wall mounted fans do not properly circulate air. The present invention eliminates the problem of stagnant air pockets created in indoor vertical farming where space is limited. Carbon dioxide may be dispersed directly onto each row of crops growing on a different shelf of a rack assembly. This process insures that each plant receives an equal quantity of carbon dioxide, as opposed to common methods of releasing carbon dioxide into a large general area with non-uniform distribution. The invention may also provide a compact air filtration system, eliminating the need for large can filters commonly used.

In one aspect, a flow distribution assembly is provided for use on a rack system having at least one shelf supported by uprights, where the shelf defines at least one plant growing region. The flow distribution assembly includes a housing, at least one duct, and a fan for directing ambient air through the housing and into the duct, so that air can be directed from the duct toward the plant growing region. The housing includes an air inlet portion and an air outlet portion, and is configured to be coupled to and supported by a first pair of the uprights. The duct has an end coupled to the housing’s air outlet portion, the duct defining a plurality of holes therealong. The duct extends linearly away from the housing, and is configured to be supported by and along the shelf to an opposite end of the ducts. The fan is fluidly coupled to the air inlet portion of the housing and is operable to direct ambient air into the housing such that the air flows away from the housing through the air outlet portion in a horizontal direction, through the duct, and through the pluralities of holes to direct air toward the plant growing region when mounted on the rack system.

In another aspect, filters may be provided on the supply side of an air circulation system. This allows for the air coming out of the fan to be disrupted, eliminating the spiral motion and pressurizes the low profile duct evenly on either side. The system creates air movement inside each rack of plants where wall fans can’t reach and space does not allow for. Optionally, carbon dioxide may be plumbed into the plenum and dispersed directly to the plants. A fan or fans may be provided with a filter to clean the air as well as circulating the air. This allows for less space to be used, lower energy costs, and the benefit of being able to change disposable filters more often at a much lower cost than “can filters”.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a side view of an embodiment of an air distribution system;

FIG. 2 is a top view of an embodiment of the air distribution system;

FIG. 3 is a front section view of an embodiment of the air intake portion of the air distribution system;

FIG. 4 is a front section view of another embodiment of the air intake portion of the air distribution system;

FIG. 5 is a top section view of an embodiment of the air intake portion of the air distribution system;

FIG. 6 is a side section view of an embodiment of the air intake portion of the air distribution system;

FIG. 7 is a bottom view of an embodiment of the air distribution system;

FIG. 8 is a front view of an embodiment of the light ballast, light bar and air distribution ducts;

FIG. 9 is a side view of a rack assembly having a air distribution system, a grow lights system and a carbon dioxide sensor system; and

FIG. 10 is a side view of an embodiment of an air distribution system on a rack system.

DETAILED DESCRIPTION

An air circulating system can be used with a vertical plant growing system to disperse air, and optionally carbon dioxide gas, to a plurality of stacked shelves that are arranged vertically in a rack placed in a room or a building. An air distribution system can be mounted over each shelf of the rack so several air distribution systems can be used with each rack. The air distribution system can perform various functions including: circulate air around each of the plants, provide an even distribution of carbon dioxide to each of the plants, and filter the recirculating air. A lighting system can also be attached to the bottom of the air distribution system that can provide continuous grow light exposure to the plants.

With reference to FIG. 1 , a side view of an embodiment of the air distribution system 100 is illustrated and with reference to FIG. 2 , a top view of an embodiment of the air distribution system 100 is illustrated. Air can be directed into an intake collar 103 mounted on an inlet portion of a filter housing 101. In an embodiment, a fan 105 can be used to push the air into the intake collar 103. The air can enter the filter housing 101 and flow through one or more filters 111. The filtered air can then flow into a plenum. An optional carbon dioxide gas inlet 113 can be coupled to the plenum and the carbon dioxide can be mixed with the filtered air. The carbon dioxide and air mixture can then flow into one or more elongated ducts 117 via respective outlet portions of the housing 101. Each duct 117 has a plurality of holes on a lower surface and the end of the duct 117 can be sealed with an end cap. The elongated ducts 117 are positioned above a plurality of plants on each shelf of the rack assembly. The carbon dioxide and air flow through the holes onto the plants, which absorb the carbon dioxide.

With reference to FIG. 2 , in an embodiment, the fan 105 can be a 10″ or a 6″ to 14″ inline fan 105 that can be mounted in the intake collar 103 at the top of the filter housing 101. The inventive system can be used with various types of vertical rack systems with plants positioned on each shelf of the rack system. The fan 105 can be mounted outside of the pallet rack volume on an end of the pallet rack. In an embodiment, the fan 105 flow rate can output 1,000 cubic feet per minute (CFM). In other embodiments, any other airflow mechanism can be used with the air distribution system to drive air through the system

With reference to FIG. 3 , a cross section front view of an embodiment of the filter housing 101 is illustrated. In this embodiment, there are two filters 111 that are held in angled positions by channel brackets 115. With reference to FIG. 4 , another cross section front view of an embodiment of the filter housing 101 is illustrated. In this embodiment, there are two filters 111 that are held in flat positions by the channel brackets 115. Air flows through the center portions of the filters 111 so the brackets 115 only contact the edges of the filters 111. In other embodiments, the filters 111 can be held by any other holding mechanisms. With reference to FIG. 5 a top sectional view of an embodiment of the filter housing 101 illustrated. A fan can be mounted within the intake collar 103 which can be attached to the air inlet on top of the filter housing 111. The fan can blow air into the filter housing 101 and through the filters 111.

With reference to FIGS. 3-5 , the filters 111 can be mounted across the width of the filter housing 101 so that air from the inlet must flow through one of the filters 111. In this example, a first filter 111 is on one side of the filter housing 101 and a second filter 111 is on an opposite side of the filter housing 101. In an embodiment with reference to FIG. 3 , the filters 111 can be angled rather than horizontally oriented within the filter housing. The edge of the filters 111 at the center of the filter housing 101 can be lower than the edges of the filters 111 at the outer sides of the filter housing 101. The filters 111 can be mounted on support structures which can be channel brackets 115 that extend across the length of the filter housing 101. In an embodiment, the support structures channel brackets 115 can have grooves that securely hold the inner and outer edges of the filters 111 in place within the filter housing 101. The filter housing 101 can have a hinged door that can be open to access the filters 111. The filters 111 can be removed and replaced when the hinged door is opened and the filters 111 can be locked in place within the filter housing 101 when the hinged door is closed.

The filters 111 can trap particulates from the plants, which can be beneficial when the plants being grown are very aromatic. Terpenes are a group of organic molecules derived from isoprene that are present in fruits, vegetables and vegetation. Terpenes are derived biosynthetically from units of isoprene and the basic molecular formula is (CsHs). These terpenes cause the specific odours for example: limonene in citrus fruit, pinene in pine tree. Marijuana is also a plant that produces terpenes. Because the smell of terpenes can be a nuisance to the surrounding areas, it can be highly beneficial to remove the marijuana terpenes that have been released into the air by the cannabis plants. In an embodiment, the filters used with the system can be terpene filters that remove terpenes from the circulating air in the plant grow building. By removing terpenes from the air, the odor generated by the building where the plants are grown can be greatly reduced so that the building is not a nuisance to the surrounding community. When the terpenes saturate the filters 111, the door to the filter housing 101 can be opened and the filters 111 can be removed and replaced with clean filters 111. The used filters 111 can be placed in sealed bags so that the odors are contained.

When the air enters the plenum through the fan 105, the air must passes through the air filters 111. In an embodiment, the filters 111 can have the dimensions, 12″×20″×1″. This process disrupts the spiraling air flow created by the fan 105 and allows both sides of the supply runs to pressurize and distribute even amounts of air through the 1.125″ duct exit holes. This was unachievable with a direct fan to supply run configuration. The process also eliminates the need for a separate fan and carbon filter to be installed in the room.

In an embodiment, a pressure sensor(s) 121 can be mounted in the filter housing 101 to measure static pressure and a differential pressure across the filters 111. This information can be used to determine the flow resistance through the filter 111 and the flow rate through the system. If a first pressure sensor 121 is mounted in the filter housing 101 upstream of the filter 111 and a second pressure sensor 121 is mounted in the filter housing 101 downstream of the filter 111, the differential pressure across the filters 111 can be measured. A clean filter 111 will allow air to more easily flow through the filter 111 and will have a lower differential pressure than a dirty filter 111. In an embodiment the system can have a processor 123 that is coupled to the pressure sensors 121 that monitor the differential pressure and the processor 123 can issue notifications when the differential pressure exceeds a predetermined value. The operator will then know that the filter(s) 111 need to replaced.

In another embodiment, the system sensor 121 and processor 123 can monitor the static pressure of the pressure up stream of the filter 111. This monitoring system can depend upon the air input providing a constant power or flow rate into the system. As the filter(s) 111 becomes dirty, the static pressure upstream of the filter(s) 111 will increase and when the upstream static pressure exceeds a predetermined value, the monitoring system can inform the operator who will then know that the filter(s) 111 need to replaced. Conversely, the system can monitor the static pressure of the pressure down stream of the filter(s) 111. As the filter(s) 111 becomes dirty, the static pressure downstream of the filter 111 will decrease and when the down stream static pressure falls below a predetermined value, the monitoring system can inform the operator who will then know that the filter(s) 111 need to replaced.

With reference to FIG. 6 , a side sectional view of the filter housing 101 is illustrated showing the carbon dioxide inlet 127 coupling attached to the bottom of the filter housing 101. The carbon dioxide inlet 127 in the illustrated example, can have a threaded insert which is bolted to the inner surface filter housing 101 which forms a seal with the filter housing 101 and prevents carbon dioxide gas leakage. An inlet coupling 127 extends from the filter housing 101. In an embodiment, the inlet coupling 127 can be a nipple which can be coupled to tubing 129 that can be used to deliver carbon dioxide to the filter housing 101. The carbon dioxide inlet coupling 127 can be coupled with tubing 129 to a carbon dioxide gas source 131 such as a carbon dioxide tank or other carbon dioxide supply. In an embodiment, a control valve 135 can be coupled between the carbon dioxide gas source 131 and the filter housing 101. The control valve 135 can be coupled to a carbon dioxide controller which can monitor the carbon dioxide levels in the building or at the plant levels. The carbon dioxide controller can maintain a predetermined carbon dioxide level by decreasing the carbon dioxide flow when the detected carbon dioxide level is too high and increase the carbon dioxide flow when the detected carbon dioxide level is too low.

With reference to FIG. 7 , a bottom view of an embodiment of distribution ducts 117 of the air distribution system 100 is illustrated. Air, and optionally carbon dioxide, flows through the ducts 117 from the proximal end attached to the filter housing 101 to the distal end of the ducts 117. The air and carbon dioxide will flow out of the holes 135 on the bottom of the ducts 117. In an embodiment, the holes 135 can be 1.125 inch diameter holes. However, in other embodiments, the holes 135 can be any suitable size such as 0.5 inch to 2.0 inch diameters.

The distribution ducts 117 can be a metal duct system made from aluminum or galvanized sheet metal. The distribution ducts 117 can be designed to be as thin as possible while still providing desired flow rate of carbon dioxide and velocity of air movement over a vertical gardening application. This can be accomplished by using a thin cross section distribution duct 117 so that the ducts consume very little vertical space. For example, the ducts 117 can have a cross section that is about 3 inches high and about 16 inches wide. This height to width (H/W) ratio can be known as the aspect ratio. In this example, the aspect ratio is 3/16=0.1875. In an embodiment, the aspect ratio of the ducts 117 is less than 0.25. The flow rate of the air and carbon dioxide can be quantified with a flow rate metric such as cubic feet per minute (CFM). The carbon dioxide and airflow eliminates warm pockets of air by providing concentrated air movement, carbon dioxide dispersion, and filtration.

In addition to providing air and optionally carbon dioxide to the plants on the rack system, embodiments of the present invention incorporate grow lights that emit light that is directed towards the plants. With reference to FIG. 8 , a front view of an embodiment of the air distribution ducts 117 and grow light bar 145 used with the air distribution system 100 is illustrated. The grow light components can include a light ballast 143, a heat sink 141 and light bars 145 which hold a plurality of light emitting diodes (LEDs). Electrical power such as 110 V AC or 220 V AC is supplied to the light ballasts 143, which provide the required electrical power to the LED grow lights in the light bars 145. The ballasts 143 can limit the amount of current from supply line voltage, while maintaining the necessary electrical conditions for proper lamp start and operation. In this embodiment, the ballast 143 can be mounted under the lower surfaces of the air ducts 117. The ducts 117 can in physical contact with the light bars 145 and the ballasts 143. The ducts 117 can function as heat sinks for heat generated by the light bars 145 and the ballast 143. The ducts 117 can be dissipate the heat from the ballasts 143 and the light bars 145 to prevent over heating. Similarly, the heat sink 141 can help to dissipate the heat generated by the ballasts 143.

With reference to FIG. 9 , a front view of another embodiment of the air distribution ducts 117 and grow lights 145 used with the air distribution system 100 is illustrated. In this embodiment, the light bar grow light bar 145 is supported by cables 149 which can be adjustable in length to adjust the height position of the light bar 145. The light bar 145 can be electrically coupled to the ballast 143 with an electrical cable 147.

With reference to FIG. 10 , the air distribution system can be used with a rack system 200 that includes a plurality of shelves 201 that provide a plurality of vertically aligned areas for growing plants 211. The ducts 117 of the air distribution system can be mounted above each of the shelves 201 so that air and optionally carbon dioxide can be delivered directly to the plants 211. The light bars 145 can also be mounted directly over the plants 211 so that exposure to the grow lights is maximized. An example of a pallet rack 200 is the Pipp Mobile Storage Systems rack shelving system that has two basic components, beams and frames, which are assembled to build racks with stacked shelves 201.

The air system can be configured to maintain a specific level of carbon dioxide in a grow room. For example, in an embodiment, the system may be configured to maintain the carbon dioxide level at approximately 1,500 ppm. The system can include carbon dioxide sensors 221 coupled to a controller 225 that controls flow control values 135 coupled to the carbon dioxide source 131. By altering the positions of the control valves 135, the flow rates of carbon dioxide to the air distribution systems can be adjusted. The controller 225 can control the flow rate to maintain an optimum carbon dioxide level and prevent the carbon dioxide level from becoming dangerous. When the carbon dioxide level is too high (for example, above, 2,000 ppm), the sensors 221 can detect this excess carbon dioxide and reduce the flow rate of carbon dioxide into the distribution system. Conversely, if the carbon dioxide level is detected as being lower than 1,000 ppm, the controller 225 can open the control vales 135 to increase the carbon dioxide levels through the air distribution system. If the carbon dioxide source 131 is a tank, a pressure sensor 137 can be mounted to the tank. If the pressure in the tank drops below a predetermined level, the system can inform the operator that the carbon dioxide tank should be replaced.

If the carbon dioxide level exceeds a level of 3,000, the system can issue a warning indicating that there can be a carbon dioxide control problem and the control system should be inspected. If the carbon dioxide level exceeds a level of 5,000, the system can issue a warning indicating that the carbon dioxide level exceeds the workplace exposure limit and warning people not to enter the room. With reference to Table 1 below a listing of carbon dioxide levels and the human reaction to exposure to the carbon dioxide gas.

TABLE 1 Listing of carbon dioxide levels and human reaction to exposure Carbon Dioxide level 250 - 350 ppm Normal carbon dioxide level in outdoor ambient air 250 - 1,000 ppm Normal carbon dioxide level in indoor air 1,000 - 2,000 ppm Poor quality air and complaints of drowsiness 2,000 - 5,000 ppm Headaches and sleepiness, increased heart rate and nausea. 5,000+ ppm Exceeds workplace exposure limit

The ducts 117 can run along the length of the rack shelves 201 and the light bars 145 can extend across the width of the shelves 201. In this embodiment, the light bars 145 can be suspended with wires or other supports below the ducts. In other embodiments, the light bars 145 can be mounted directly to the bottom of the ducts 117. In an embodiment, the height of the light bars 145 over the plants 211 can be adjustable. The light bars 145 can be positioned so that the LED lights may be 12-18 inches above the plants 221. As the plants 211 grow, the vertical positions of the light bars 145 may be adjusted to provide the optimum grow light exposure to the plants 211.

The present disclosure, in various embodiments, includes components, methods, processes, systems and/or apparatus substantially as depicted and described herein, including various embodiments, subcombinations, and subsets thereof. Those of skill in the art will understand how to make and use the present disclosure after understanding the present disclosure. The present disclosure, in various embodiments, includes providing devices and processes in the absence of items not depicted and/or described herein or in various embodiments hereof, including in the absence of such items as may have been used in previous devices or processes, e.g., for improving performance, achieving ease and/or reducing cost of implementation. Rather, as the flowing claims reflect, inventive aspects lie in less than all features of any single foregoing disclosed embodiment. 

1. A flow distribution assembly for use in providing air flow to growing plants on a rack, said distribution assembly comprising: an air system configured to be supported on a rack system having a plurality of uprights and a plurality of shelves supported by the uprights, the shelves defining vertically aligned plant growing areas, said air system comprising: a housing comprising an air inlet portion and an air outlet portion, said housing configured for mounting at a pair of the uprights; a fan coupled to said air inlet portion of said housing; and a first elongated duct having a first plurality of holes arranged to direct air at one of the plant growing areas when mounted on the rack, wherein said first elongated duct has an end coupled to said outlet portion of said housing and extends linearly, and is configured to be supported by and along one of the shelves to an opposite end of said first elongated duct; wherein said fan is configured to direct ambient air in a vertical direction into said housing and out through said outlet portion such that the air flows away from said housing in a horizontal direction through said first elongated duct and out through said first plurality of holes in said first elongated duct.
 2. The flow distribution assembly of claim 1, further comprising an intake collar mounted at said inlet portion of said housing.
 3. The flow distribution assembly of claim 2, wherein said fan is coupled directly to said intake collar and positioned laterally outboard of the vertically aligned plant growing areas.
 4. The flow distribution assembly of claim 1, further comprising a second elongated duct having a second plurality of holes on a lower surface of said second elongated duct, said second elongated duct comprising an end coupled to a second outlet portion of said housing, wherein said second elongated duct extends linearly, and is configured to be supported by and along the one of the shelves to an opposite end of said second elongated duct.
 5. The flow distribution assembly of claim 4, wherein said first elongated duct and second elongated duct define an elongate space therebetween, said elongate space extending uninterrupted from the ends of said first and second elongated ducts to said opposite ends of said first and second elongated ducts.
 6. The flow distribution assembly of claim 1, wherein said fan and said air inlet portion are configured so that air flows downwardly through said fan and said air inlet portion.
 7. The flow distribution assembly of claim 1, further comprising a filter positioned between said air inlet portion and said outlet portion of said housing.
 8. A flow distribution assembly for use on a rack system having at least one shelf supported by first and second pairs of uprights, the at least one shelf defining at least one plant growing region, said flow distribution assembly comprising: a housing configured to be coupled to and supported by the first pair of uprights, said housing having an air inlet portion and first and second air outlet portions; first and second elongated ducts having ends coupled to respective ones of said first and second air outlet portions, said first and second elongated ducts defining respective first and second pluralities of holes therealong, wherein said first and second elongated ducts extend linearly away from said housing and alongside one another, wherein said ducts are configured to be supported by and along the at least one shelf to respective opposite ends of said first and second elongated ducts; and a fan fluidly coupled to said air inlet portion of said housing and operable to direct ambient air into said housing such that the air flows away from said housing through said air outlet portions in a horizontal direction, through said first and second elongated ducts, and through said first and second pluralities of holes to direct air toward the at least one plant growing region when mounted on the rack system.
 9. The flow distribution assembly of claim 8, wherein said elongate space extends uninterrupted from said ends of said first and second elongated ducts to said opposite ends of said first and second elongated ducts.
 10. The flow distribution assembly of claim 8, wherein said first plurality of holes is along a lower surface of said first elongated duct.
 11. The flow distribution assembly of claim 8, wherein said air inlet portion of said housing is positioned laterally outboard of the first pair of uprights and the at least one plant growing region.
 12. The flow distribution assembly of claim 11, wherein said fan is positioned laterally outboard of the first pair of uprights and the at least one plant growing region.
 13. The flow distribution assembly of claim 12, wherein said fan and said air inlet portion are configured so that air flows downwardly through said fan and said air inlet portion.
 14. The flow distribution assembly of claim 8, wherein said first and second elongated ducts are positioned at opposite sides of said air inlet portion.
 15. The flow distribution assembly of claim 8, wherein said housing defines a plenum between said air inlet portion and said air outlet portion.
 16. The flow distribution assembly of claim 8, further comprising a filter positioned between said air inlet portion and said first and second air outlet portions of said housing.
 17. An apparatus kit for dispersing air, comprising: an air system configured to be mounted on and supported by a rack system having a plurality of uprights and at least one shelf that defines at least one plant growing area and is mountable to the uprights, said air system comprising: a housing comprising an air inlet portion and an air outlet portion, said housing defining a plenum between said air inlet and outlet portions, wherein said air inlet portion is configured to be positioned at and supported between a pair of the uprights; a fan configured to be coupled to said air inlet portion of said housing; and a first elongated duct having a first plurality of holes arranged to direct air at the at least one plant growing area when mounted on the rack system, wherein said first elongated duct has an end configured for coupling to said outlet portion of said housing, and is configured to extend linearly along the rack system and be supported by the rack system to an opposite end of said first elongated duct; wherein said fan is operable to direct ambient air into said housing such that the air flows away from said housing in a horizontal direction through said first elongated duct and through said first plurality of holes in said first elongated duct.
 18. The apparatus kit of claim 17, wherein said first plurality of holes is arranged along a lower surface of said first elongated duct so that air flows downwardly out through said first plurality of holes.
 19. The apparatus kit of claim 18, further comprising a second elongated duct having a second plurality of holes on a lower surface of said second elongated duct, and said second elongated duct is configured for coupling to a second outlet portion of said housing.
 20. The apparatus kit of claim 17, wherein said air inlet portion of said housing is configured to be positioned laterally outboard of the first pair of uprights and the at least one plant growing area.
 21. The apparatus kit of claim 20, wherein said fan is configured to be positioned laterally outboard of the first pair of uprights and the at least one plant growing area.
 22. The apparatus kit of claim 17, further comprising a filter configured to be positioned between said air inlet portion and said air outlet portion of said housing. 